Modular fork assembly for a material-handling vehicle

ABSTRACT

A modular fork assembly for a pallet truck includes a discrete elongate body, a discrete load wheel module, and a discrete fork tip that may be detachably connected by the same or different types of interlocking mechanisms that are adapted to inhibit sheer forces. The load wheel module includes a frame and a load wheel assembly that includes a load wheel that is operatively connected to the frame.

TECHNICAL FIELD

The field of this disclosure relates generally to forked vehiclesconfigured to transport goods and materials. More specifically, thisdisclosure relates to fork assemblies for pallet trucks.

BACKGROUND INFORMATION

Material-handling vehicles, such as forked vehicles, are presentedherein only by way of example to pallet trucks. Typical pallet truckssupport one, two in-line, or three in-line standard size pallets.Typically, pallet trucks include lifting load forks that are welded attheir rear end or heel end to a chassis or battery box. The forkstypically include an elongate body welded to elongate steel tubes toprovide support. The front end of the forks typically includes supportrollers. A hydraulic system, which is located in proximity to thechassis or battery box, operates a lifting mechanism that moves thesupport rollers, and lifts the chassis or battery box and the forkstogether with goods, such as pallets loaded thereon. The support rollersare typically coupled to the lift mechanism by a mechanical linkage thattransmits force from a hydraulic lifting cylinder to the supportrollers. A valve arrangement is provided to relieve the hydraulicpressure in the lifting cylinder, thus lowering and placing the load onthe floor. Steer wheels are located behind the battery box. A steeringmechanism, such as a tiller, also may be provided to steer the steerwheels relative to the chassis and forks.

OVERVIEW OF DISCLOSURE

This overview is provided to introduce a selection of concepts in asimplified form that are further described in greater detail later. Thisoverview is not intended to identify key or essential inventive conceptsof the claimed subject matter, nor is it intended for limiting the scopeof the claimed subject matter.

One aspect of this disclosure relates to fork assemblies that includemodular detachable components.

Another aspect of this disclosure relates to load wheel modules thatcontain a hydraulic actuator.

In one embodiment, a fork assembly for a forked material-handling truck(e.g., pallet truck) comprises a discrete elongate body; a discrete loadwheel module; a first interlocking mechanism configured for detachableconnection of the elongate body to the load wheel module; a discretefork tip; and a second interlocking mechanism configured for detachableconnection of the load wheel module to the fork tip.

In some additional, alternative, or selectively cumulative embodiments,a load wheel module for a fork assembly for a forked material-handlingtruck (e.g., pallet truck) comprises a frame; a load wheel assembly,including a load wheel, operatively connected to the frame; and ahydraulic actuator contained within the frame and operatively connectedto the load wheel assembly to lower the load wheel hydraulically.

In some additional, alternative, or selectively cumulative embodiments,an inventory of parts for a fork assembly for a forked material-handlingtruck (e.g., pallet truck) comprises multiple interchangeable elongatebodies; multiple interchangeable load wheel modules; multipleinterchangeable fork tips; and multiple operatively identicalinterlocking mechanism components configured for detachable connectionof any one of the elongate bodies to any one of the load wheel modulesand configured for detachable connection of any one of the fork tips toany one of the load wheel modules.

In some additional, alternative, or selectively cumulative embodiments,a forked material-handling truck (e.g., pallet truck) including a forkassembly comprises a steer wheel; a chassis operatively connected to thesteer wheel; and two substantially parallel forks operatively connectedto and extending from the chassis and configured to hold a load forconveyance by the pallet truck as the pallet truck moves, the forksincluding a first fork and a second fork, wherein the first forkcomprises a first elongate body, a first load wheel module, a firstinterlocking mechanism configured for detachable connection of the firstelongate body to the first load wheel module, a first fork tip, and asecond interlocking mechanism configured for detachable connection ofthe first load wheel module to the first fork tip, wherein the secondfork comprises a second elongate body, a second load wheel module, athird interlocking mechanism configured for detachable connection of thesecond elongate body to the second load wheel module, a second fork tip,and a fourth interlocking mechanism configured for detachable connectionof the second load wheel module to the second fork tip.

In some additional, alternative, or selectively cumulative embodiments,a method for deploying a load wheel of a forked material-handling truck(e.g., pallet truck) in response to a load wheel deployment signalcomprises providing hydraulic power through a hydraulic line positionedwithin an elongate body of a fork assembly; employing the hydraulicpower from the hydraulic line to actuate multiple pistons of an actuatorpositioned within a load wheel module of the fork assembly, wherein theload wheel module has a load wheel module frame that is operativelyconnected to the elongate body; and employing the multiple pistons todeploy the load wheel so that it is vertically spaced apart from theload wheel module frame.

In some additional, alternative, or selectively cumulative embodiments,a method of assembling a fork for a forked material-handling vehiclecomprises detachably connecting a modular elongate body to a modularload wheel module; and detachably connecting the modular load wheelmodule to a modular fork tip.

In some additional, alternative, or selectively cumulative embodiments,a fork for a forked material-handling vehicle comprises a frame; a wheeloperatively connected to the frame; and a hydraulic actuator containedwithin the frame and operatively connected to the wheel to lower thewheel hydraulically, the hydraulic actuator having an input forconnection to a hydraulic hose running along a portion of the length ofthe fork from a hydraulic pressure source.

In some additional, alternative, or selectively cumulative embodiments,the first interlocking mechanism and the second interlocking mechanismare substantially identical.

In some additional, alternative, or selectively cumulative embodiments,the first interlocking mechanism and the second interlocking mechanismcontain a substantially identical component.

In some additional, alternative, or selectively cumulative embodiments,the first interlocking mechanism and the second interlocking mechanismare operatively identical.

In some additional, alternative, or selectively cumulative embodiments,the first interlocking mechanism and the second interlocking mechanismare interchangeable.

In some additional, alternative, or selectively cumulative embodiments,the first interlocking mechanism and the second interlocking mechanismcontain an interchangeable component.

In some additional, alternative, or selectively cumulative embodiments,the first and second load wheel modules are interchangeable, the firstand second tips are interchangeable, the first and third interlockingmechanisms are operatively identical, and the second and fourthinterlocking mechanisms are operatively identical.

In some additional, alternative, or selectively cumulative embodiments,the first interlocking mechanism and the second interlocking mechanismcontain a reusable component.

In some additional, alternative, or selectively cumulative embodiments,at least one of the first interlocking mechanism and the secondinterlocking mechanism employs one or more mated pairs of internallythreaded receptacles and externally threaded fasteners.

In some additional, alternative, or selectively cumulative embodiments,the externally threaded fasteners have a minimum diameter of about 12mm.

In some additional, alternative, or selectively cumulative embodiments,at least one of the first interlocking mechanism and the secondinterlocking mechanism employs mated shear-resistant features, includingfirst and second sheer-resistant features.

In some additional, alternative, or selectively cumulative embodiments,the first sheer-resistant feature includes a protruding feature and thesecond sheer-resistant feature includes a receiving feature.

In some additional, alternative, or selectively cumulative embodiments,the first interlocking mechanism includes a first protruding featurethat is mated to a first receiving feature, wherein one of the firstprotruding feature and the first receiving feature is permanentlyconnected to or associated with the elongate body, wherein a differentone of the first protruding feature and the first receiving feature ispermanently connected to or associate with the load wheel module.

In some additional, alternative, or selectively cumulative embodiments,the sheer-resistant features are configured to receive a fastener.

In some additional, alternative, or selectively cumulative embodiments,the first interlocking mechanism employs a first internally threadedreceptacle that is mated to a first externally threaded fastener,wherein one of the first internally threaded receptacle and firstexternally threaded fastener is configured to connect to the elongatebody, and wherein a different one of the first internally threadedreceptacle and the first externally threaded fastener is configured toconnect to the load wheel module.

In some additional, alternative, or selectively cumulative embodiments,both of the first protruding feature and the first receiving feature areconfigured to receive the first externally threaded fastener.

In some additional, alternative, or selectively cumulative embodiments,the first interlocking mechanism includes a first endcap that isattached to the elongate body and includes a first sheer-resistant bodyfeature that is mated to a first sheer-resistant module feature of theload wheel module.

In some additional, alternative, or selectively cumulative embodiments,the first sheer-resistant body feature and the first sheer-resistantmodule feature are adapted to receive a fastener.

In some additional, alternative, or selectively cumulative embodiments,the first endcap is welded to the elongate body.

In some additional, alternative, or selectively cumulative embodiments,the second interlocking mechanism includes a second endcap that isattached to the fork tip and includes a second sheer-resistantattachment feature that is mated to a second sheer-resistant modulefeature of the load wheel module, wherein the first and secondinterlocking mechanisms are operatively identical.

In some additional, alternative, or selectively cumulative embodiments,the second interlocking mechanism includes a second endcap that isattached to the fork tip and includes a second sheer-resistantattachment feature that is mated to a second sheer-resistant modulefeature of the load wheel module.

In some additional, alternative, or selectively cumulative embodiments,the second sheer-resistant attachment feature and the secondsheer-resistant module feature are adapted to receive a fastener.

In some additional, alternative, or selectively cumulative embodiments,the elongate body has a first characterizing color, wherein the loadwheel module has a second characterizing color, wherein the fork tip hasa third characterizing color, and wherein the first, second, and thirdcharacterizing colors are different.

In some additional, alternative, or selectively cumulative embodiments,the load wheel module has opposing ends having substantially identicalsheer-resistant features.

In some additional, alternative, or selectively cumulative embodiments,the elongate body includes a channel along its length, and wherein anendcap associated with the first interlocking mechanism includes anaperture that aligns with the channel.

In some additional, alternative, or selectively cumulative embodiments,the fork tip includes a proximal connection end for attachment closestto the load wheel module, wherein the proximal end has proximal enddimensions, wherein the fork tip includes a distal end that has distalend dimensions, and wherein at least one of the distal end dimensions issmaller than a respective one of the proximal end dimensions.

In some additional, alternative, or selectively cumulative embodiments,the pallet truck comprises: a hydraulic power source; and a firsthydraulic line positioned through the first elongate body, wherein thefirst hydraulic line transmits hydraulic fluid from the hydraulic powersource to a first hydraulic actuator positioned within the first loadwheel module.

In some additional, alternative, or selectively cumulative embodiments,the load wheel module comprises: a frame; a load wheel assembly,including a load wheel, operatively connected to the frame; and ahydraulic actuator contained within the frame and operatively connectedto the load wheel assembly to lower the load wheel hydraulically.

In some additional, alternative, or selectively cumulative embodiments,the load wheel module comprises a frame; a load wheel assembly,including a load wheel, operatively connected to the frame; and amechanical link operatively coupled to the load wheel assembly to lowerthe load wheel, wherein the mechanical link extends through the discreteelongate body.

In some additional, alternative, or selectively cumulative embodiments,the pallet truck comprises a power source and a first mechanical linkpositioned through the first elongate body, wherein the first mechanicallink transmits force from the power source to a first load wheelmechanism positioned within the first load wheel module.

In some additional, alternative, or selectively cumulative embodiments,the pallet truck comprises: first and second elongate bodies having afirst characterizing color, first and second load wheel modules having asecond characterizing color, first and second fork tips having a thirdcharacterizing color, wherein the first, second, and thirdcharacterizing colors are different.

In some additional, alternative, or selectively cumulative embodiments,the hydraulic actuator includes a hydraulic line input connectoroperative for connecting the hydraulic actuator to a hydraulic line thattransmits hydraulic fluid from a hydraulic power source.

In some additional, alternative, or selectively cumulative embodiments,hydraulic power from the hydraulic power source has a maximum pressurewithin the range of about 2,000 to about 4,000 psi at the hydraulic lineinput connector.

In some additional, alternative, or selectively cumulative embodiments,the hydraulic actuator includes multiple pistons.

In some additional, alternative, or selectively cumulative embodiments,the multiple pistons are hydraulically connected to a hydraulicmanifold.

In some additional, alternative, or selectively cumulative embodiments,the hydraulic manifold is hydraulically connected to a hydraulic lineinput connector operative for connecting the hydraulic actuator to ahydraulic line that transmits hydraulic fluid from a hydraulic powersource.

In some additional, alternative, or selectively cumulative embodiments,at least one of the pistons has a length within the range of about 0.50inches to about 3 inches (about 1.27 to about 7.62 cm) and a strokelength within the range of about 1 to about 3 inches (about 2.54 toabout 7.62 cm).

In some additional, alternative, or selectively cumulative embodiments,at least one of the pistons has a length within the range of about 1 toabout 2 inches (about 2.54 to about 5.08 cm) and a stroke length withinthe range of about 1.5 to about 2.5 inches (about 3.81 to about 6.35cm).

In some additional, alternative, or selectively cumulative embodiments,the hydraulic actuator includes at least three pistons.

In some additional, alternative, or selectively cumulative embodiments,the hydraulic actuator includes at least four pistons.

In some additional, alternative, or selectively cumulative embodiments,the hydraulic actuator is operable to provide maximum thrust within arange of about 66,723 newtons (about 15,000 pounds) to about 133,446newtons (about 30,000 pounds).

In some additional, alternative, or selectively cumulative embodiments,the hydraulic actuator is operable to provide greater than about 66,723newtons (about 15,000 pounds) of thrust.

In some additional, alternative, or selectively cumulative embodiments,the hydraulic actuator is operable to provide greater than about 88,964newtons (about 20,000 pounds) of thrust.

In some additional, alternative, or selectively cumulative embodiments,the hydraulic actuator is operatively connected to the load wheel moduleframe.

In some additional, alternative, or selectively cumulative embodiments,the frame includes a fork tip-facing end and a body-facing end, andwherein the actuator is positioned closer to the body-facing end than tothe fork tip-facing end.

In some additional, alternative, or selectively cumulative embodiments,the body-facing end includes an aperture adapted to accommodate ahydraulic line that transmits hydraulic fluid from a hydraulic powersource to the hydraulic actuator.

In some additional, alternative, or selectively cumulative embodiments,the load wheel module comprises: a first attachment feature of a firstinterlocking mechanism configured for detachable connection of thebody-facing end of the frame to an elongate body; and a secondattachment feature of a second interlocking mechanism configured fordetachable connection of the fork tip-facing end of the frame to a forktip.

In some additional, alternative, or selectively cumulative embodiments,at least one of the first and second attachment features includes asheer-resistant module feature that is mated to a sheer-resistantfeature of the elongate body or the fork tip.

In some additional, alternative, or selectively cumulative embodiments,the sheer-resistant module feature includes one or more receivingfeatures.

In some additional, alternative, or selectively cumulative embodiments,the load wheel module frame includes a fork tip-facing end and abody-facing end, wherein the load wheel is positioned closer to the forktip-facing end than to the body-facing end.

In some additional, alternative, or selectively cumulative embodiments,the load wheel is one of multiple load wheels that are part of the loadwheel module.

In some additional, alternative, or selectively cumulative embodiments,the hydraulic actuator and the load wheel assembly form a wheel modulesubstructure, wherein the load wheel assembly includes a load wheel unitand a wheel carrier strut that are operatively connected to each other,and wherein the wheel carrier strut is operatively connected tohydraulic actuator and the frame.

In some additional, alternative, or selectively cumulative embodiments,the wheel carrier strut is pivotally connected to hydraulic actuator andpivotally connected to the frame, and wherein the wheel carrier strut ispivotally connected to the load wheel unit.

Selectively cumulative embodiments are embodiments that include anycombination of multiple embodiments that are not mutually exclusive.

Additional aspects and advantages will be apparent from the followingdetailed description of example embodiments, which proceeds withreference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a front left isometric view of a prior-art lift forkassembly, showing a pair of forks welded to a battery box.

FIG. 1B illustrates a cross-sectional view of a prior-art elongate bodyof a lift fork.

FIG. 2 illustrates a front left partly exploded isometric view of anexample battery box and a fork assembly showing the fork assemblydisassembled from the battery box, according one embodiment.

FIG. 3A illustrates a top plan view of a fork assembly, according oneembodiment.

FIG. 3B illustrates a right-side elevation view of the fork assemblyshown in FIG. 3A.

FIG. 3C illustrates a bottom view of the fork assembly shown in FIG. 3A.

FIG. 3D illustrates a bottom right isometric view of a portion of thefork assembly, showing components of an embodiment of a firstinterlocking mechanism.

FIG. 4A illustrates a front right partly exploded isometric view of aportion of the fork assembly shown in FIG. 3A.

FIG. 4B illustrates a front right exploded isometric view of a portionof the fork assembly, showing components of an embodiment of a firstinterlocking mechanism.

FIG. 4C illustrates a front right exploded isometric view of a portionof the fork assembly, showing components of an embodiment of a secondinterlocking mechanism.

FIG. 4D illustrates a front right isometric view of an embodiment of anendcap.

FIG. 4E illustrates a bottom rear right isometric view of an embodimentof an endcap.

FIG. 4F illustrates a rear left bottom isometric view of a body-facingend of a load wheel module, according to one embodiment.

FIG. 5A illustrates a front right isometric view of an elongate body ofthe fork assembly shown in FIG. 3A.

FIG. 5B illustrates a cross-sectional view of the elongate body shown inFIG. 5A.

FIG. 6A illustrates a front left isometric view of an elongate body,according to an alternative embodiment.

FIG. 6B illustrates a cross-sectional view of the elongate body shown inFIG. 6A.

FIG. 6C illustrates a front left isometric view of an elongate body,according to another alternative embodiment.

FIG. 7 illustrates a cross-sectional view of an elongate body portion,according to another alternative embodiment.

FIG. 8A illustrates a front right bottom isometric view of a portion ofan elongate body showing an endcap, according to one embodiment.

FIG. 8B illustrates a top front right isometric view of an elongate bodyof a fork assembly, wherein the elongate body is attached to endcaps,according to one embodiment.

FIG. 8C illustrates a top front right enlarged isometric view of aportion of an elongate body showing an endcap, according to oneembodiment.

FIG. 9A illustrates a front right bottom isometric view of a load wheelmodule of a fork assembly, showing an undeployed load wheel unit,according to one embodiment.

FIG. 9B illustrates a front right bottom isometric view of a load wheelmodule of a fork assembly, showing a deployed load wheel unit, accordingto one embodiment.

FIG. 9C illustrates a front right top isometric view of a wheel modulesubstructure of a load wheel module, according to one embodiment.

DETAILED DESCRIPTION OF EMBODIMENTS

Example embodiments are described below with reference to theaccompanying drawings. Unless otherwise expressly stated in thedrawings, the sizes, positions, etc., of components, features, elements,etc., as well as any distances therebetween, are not necessarily toscale, and may be disproportionate and/or exaggerated for clarity.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an” and “the” are intended to includethe plural forms as well, unless the context clearly indicatesotherwise. It should be recognized that the terms “comprise,”“comprises,” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,elements, components, and/or groups thereof. Unless otherwise specified,a range of values, when recited, includes both the upper and lowerlimits of the range, as well as any sub-ranges therebetween. Unlessindicated otherwise, terms such as “first,” “second,” etc., are onlyused to distinguish one element from another. For example, one elementcould be termed a “first element” and similarly, another element couldbe termed a “second element,” or vice versa. The section headings usedherein are for organizational purposes only and are not to be construedas limiting the subject matter described.

Unless indicated otherwise, the terms “about,” “thereabout,”“substantially,” etc. mean that amounts, sizes, formulations,parameters, and other quantities and characteristics are not and neednot be exact, but may be approximate and/or larger or smaller, asdesired, reflecting tolerances, conversion factors, rounding off,measurement error and the like, and other factors known to those ofskill in the art.

Spatially relative terms, such as “right,” left,” “below,” “beneath,”“lower,” “above,” and “upper,” and the like, may be used herein for easeof description to describe one element's or feature's relationship toanother element or feature, as illustrated in the drawings. It should berecognized that the spatially relative terms are intended to encompassdifferent orientations in addition to the orientation depicted in thefigures. For example, if an object in the figures is turned over,elements described as “below” or “beneath” other elements or featureswould then be oriented “above” the other elements or features. Thus, theterm “below” can, for example, encompass both an orientation of aboveand below. An object may be otherwise oriented (e.g., rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may be interpreted accordingly.

Unless clearly indicated otherwise, all connections and all operativeconnections may be direct or indirect. Similarly, unless clearlyindicated otherwise, all connections and all operative connections maybe rigid or non-rigid.

Like numbers refer to like elements throughout. Thus, the same orsimilar numbers may be described with reference to other drawings evenif they are neither mentioned nor described in the correspondingdrawing. Also, even elements that are not denoted by reference numbersmay be described with reference to other drawings.

Many different forms and embodiments are possible without deviating fromthe spirit and teachings of this disclosure and so this disclosureshould not be construed as limited to the example embodiments set forthherein. Rather, these example embodiments are provided so that thisdisclosure will be thorough and complete, and will convey the scope ofthe disclosure to those skilled in the art.

FIG. 1A illustrates a front left isometric view of a prior-art fork andbattery box assembly 5 having a pair of forks 10 welded to a battery box15, and FIG. 1B illustrates a cross-sectional view of a prior artelongate body of a lift fork 10. As is typical with conventional pallettrucks, each of the forks 10 is made of multiple components (such as aload-bearing surface 11 and support tubes 13) connected by longitudinalwelds 17 to form a unitary structure that is welded to the battery box15 and to a torsion member 20.

One challenge faced by pallet truck manufacturers is that customersoften want varying fork configurations, such as forks with variablespreads, lengths, tips, and widths. Because forks are typicallymanufactured in standard sizes, changing fork parameters requires costlyand time-consuming retooling to modify the battery box and/or forkdesign to produce a pallet truck conforming to individual customerspecifications. In some situations, such redesigns can add up to sixweeks of lead-time. In addition, stocking multiple lengths of forks mayrequire a significant capital outlay for inventory. Some of these issuescan be addressed by the development of a modular fork assembly withdetachably connectable components that couples directly or indirectly tothe battery box, chassis, or other part connected to the chassis.

FIG. 2 illustrates a front left isometric view of an example of a forkand battery box assembly 25 with a modular fork assembly 30 disassembledfrom a battery box 35 of a pallet truck, such as one of the HYSTERW45ZHD2 or YALE MPB045ZH manufactured by the Hyster-Yale Group, 5200Martin Luther King Junior Highway, Greenville, N.C. 27834. A typicalfork and battery box assembly 25 includes one battery box 35 andmultiple modular fork assemblies 30 (such as two modular fork assemblies30), though only one modular fork assembly 30 is depicted in FIG. 2. Themodular fork assemblies 30 may be coupled to the battery box 35 bywelding or by locking. Locking a modular fork assembly 30 to the batterybox 35, the torsion member 20, or both, means that the modular forkassembly 30 can also be unlocked from the battery box 35, the torsionmember 20, or both.

The modular fork assembly 30 may be coupled to the battery box 35through one or more intermediary couplers or interlocking mechanisms,such as an optional heel 45 shown in FIG. 2. The optional heel 45 can beconnected to the elongate body 50, for example, by welding or othersuitable attachment, such as later described. A proximal end 40 (alsoreferred to as a heel end) of the elongate body 50 is the end closest tothe battery box 35. As illustrated, the proximal end 40 of the modularfork assembly 30 is coupled to the heel 45, which is configured to belocked to the battery box 35 and/or the torsion member 20; however, theproximal end 40 of the modular fork assembly 30 may be welded orotherwise coupled directly to the battery box 35 and/or the torsionmember 20 with or without employing a separate optional heel 45.

The battery box 35 is sized to fit a battery or battery array. When usedin conjunction with a pallet truck, pallet jack, or other suitableforklift, the entire fork and battery box assembly 25 may be raised andlowered as a single unit, for example via a hydraulic cylinder actuatedby hydraulic power from a hydraulic power source (not shown). The twomodular fork assemblies 30 may be referred to as a right modular forkassembly and a left modular fork assembly, depending on the side of thebattery box 35 to which they are coupled. These right and left modularfork assemblies may be identical such that one modular fork assembly maybe swapped for the other.

FIG. 3A, FIG. 3B, and FIG. 3C (collectively FIG. 3) illustraterespective top plan, right side elevation, bottom, and bottom rightisometric views of an example of a modular fork assembly 30. FIG. 4Aillustrates a front right partly exploded isometric view of a portion ofthe modular fork assembly 30 shown in FIG. 3A; FIG. 4B illustrates afront right exploded isometric view of a portion of the modular forkassembly 30, showing components of an embodiment of a first interlockingmechanism 365; FIG. 4C illustrates a front right exploded isometric viewof a portion of the modular fork assembly, showing components of anembodiment of a second interlocking mechanism 675; FIG. 4D illustrates afront right isometric view of an embodiment of an endcap 360; FIG. 4Eillustrates a bottom rear right isometric view of an embodiment of theendcap 360; and FIG. 4F illustrates a rear left bottom isometric view ofa body-facing end 65 of the load wheel module 55.

With reference to FIG. 3 and FIGS. 4A, 4B, 4C, 4D, 4E, and 4F(collectively FIG. 4) each modular fork assembly 30 includes multiplecomponents. A fully assembled modular fork assembly 30 includes anelongate body 50, a load wheel module 55, and a fork tip 60 (alsoreferred to as a fork toe). A proximal or body-facing end 65 of the loadwheel module 55 can be detachably connected to a distal end 70 (oppositethe proximal end 40) of the elongate body 50, the distal end 70 beingfurthest from the battery box 35. And, the fork tip 60 can be detachablyconnected to a distal or fork tip-facing end 75 of the load wheel module55. The elongate body 50, the load wheel module 55, and the fork tip 60may be randomly selected from an inventory of respective substantiallyidentical elongate bodies 50, load wheel modules 55, and fork tips 60.To facilitate ease of storage and assembly, the elongate bodies 50 mayhave a first characterizing color; the load wheel modules 55 may have asecond characterizing color; and the fork tips 60 may have a thirdcharacterizing color, wherein the first, second, and thirdcharacterizing colors are different.

For convenience and modularity, the optional heel 45, the elongate body50, and the fork tip 60 may be identical for both the left and rightmodular fork assemblies 30 (e.g. the fork assemblies 30 coupled to theleft and right sides of the battery box 35). Using identical componentsfor both the left and right fork assemblies 30 increases the modularityof the system over a system in which the left and right forks are madewith distinct, non-interchangeable components. However, distinct,non-identical exchangeable components may be used to create differentleft and right modular fork assemblies 30. For example, the elongatebody 50 may be made in any desired length, detachably coupled to one ofseveral different designs for the load wheel module 55, which is in turndetachably coupled to a desired fork tip 60 to create a customizablemodular fork assembly 30 to accommodate a wide range of customerpreferences.

Although a fork body of conventional cross-sectional construction can beemployed, the elongate body 50 can alternatively be formed such thatthinner and/or lighter materials may be used compared to existing forkbodies while providing excellent dimensional stability and reducingmaterials costs and/or weight. In some embodiments, the elongate body 50may include no more than two longitudinal weldments, or no more than onelongitudinal weldment. In some embodiments, the method further includesforming a longitudinal weldment to join the first longitudinal edge andthe second longitudinal edge of the steel sheet; and, in particularembodiments, the longitudinal weldment may extend the full length of theelongate body portion.

Additionally, manufacturing processes that avoid the need to separatelyweld multiple parts together may be used, such as roll forming, additivemanufacturing, or extrusion processes. One method of making the elongatebody 50 for the modular fork assembly 30 includes using a rollingprocess to form a steel sheet into the elongate body 50, which mayinclude an understructure 80 and a load-bearing upper structure 85. Therolling process may be a cold rolling process wherein the shape of theunderstructure is designed to be integrally strong so as to besubstantially weldless or employ a few welds out of an abundance ofcaution. Alternatively a hot or warm rolling process may provideself-melding between components of the elongate body 50 that touch eachother. The rolling process can be a continuous process that forms allthe components of a cross section of the elongate body 50. Anothermethod includes using an extrusion process to form the elongate bodyportion 50. The optional use of such processes to form the elongate body50 reduces the assembly and welding costs typically associated withconventional fork manufacture. These and other features provide acompetitive advantage and differentiator in an exceedingly crowdedmarket.

FIG. 5A and FIG. 5B (collectively FIG. 5) illustrate a front rightisometric view and a cross-sectional view, respectively, of an exampleof an elongate body 50 of a fork assembly 30. With reference to FIG. 5,the elongate body 50 may include an exemplary understructure 80 coupledto a load-bearing upper structure 85, which may form an upper surface115 of the elongate body 50. The understructure 80 forms a structuralelement that resists one or more of flex, torsion, axial compression,and/or lateral deflection of the load-bearing upper structure 85. Theunderstructure 80 may include a first truss 90 and a second truss 95.The first truss 90 may include a first strut 100 that extends downwardfrom the outer edge of the load-bearing upper structure 85 in agenerally orthogonal orientation with respect to the load-bearing upperstructure 85. A first cross beam 105 is coupled to the first strut 100and extends away from the first strut 100, for example, substantiallyorthogonally from the first strut 100 (toward a longitudinal midline 110of the elongate body 50) to form a lower surface 120 of the elongatedbody 50. A second strut 125 may be coupled to the first cross beam 105and may extend from the first cross beam 105 toward the load-bearingupper structure 85.

A second cross beam 130 may be coupled to the second strut 125 and maycontact the lower surface 135 of the load-bearing upper structure 85.The second cross beam 130 may be optionally coupled to the load-bearingupper structure 85, for example, via spot welds or by being integrallyformed with the load-bearing upper structure 85. A third strut 140 iscoupled to the second cross beam 130 and extends from the second crossbeam 130 away from the load-bearing upper structure 85. A third crossbeam 145 is coupled to the third strut 140 and extends away from thethird strut 140 (toward the midline 110 of the elongate body 50) to formanother lower surface 120 of the elongate body 50. A fourth strut 150extends from the third cross beam 145 towards the load-bearing upperstructure 85 and may be coupled to the load-bearing upper structure 85.

The second truss 95 comprises a fifth strut 155 that extends downwardfrom the load-bearing upper structure 85 and may be coupled to theload-bearing upper structure 85. A fourth cross beam 160 is coupled tothe fifth strut 155 and extends away from the fifth strut 155, forexample, substantially orthogonally from the fifth strut 204 (away fromthe longitudinal midline 110 of the elongate body 50) to form anotherlower surface 120 of the elongated body 50. A sixth strut 165 is coupledto the fourth cross beam 160 and extends from the fourth cross beam 165towards the load-bearing upper structure 85.

A fifth cross beam 170 is coupled to the sixth strut 165 and contactsthe lower surface 135 of the load-bearing upper structure 85. The fifthcross beam 170 is optionally coupled to the load-bearing upper structure85, for example, via spot welds or by being integrally formed with theload-bearing upper structure 85. A seventh strut 175 is coupled to thefifth cross beam 170 and extends from the fifth cross beam 170 away fromthe load-bearing upper structure 85. A sixth cross beam 180 is coupledto the seventh strut 175 and extends away from the seventh strut 175(away from the midline 110 of the elongate body 150) to form anotherlower surface 120 of the elongate body 50. An eighth strut 185 extendsfrom the sixth cross beam 180 towards the load-bearing upper structure85 and may be coupled to the load-bearing upper structure 85. The strutsmay be generally vertical, or one or more of the struts may be angledwith respect to the plane(s) of first and second surface zones 190 and195 of the load-bearing upper structure 85.

The load-bearing upper structure 85 and/or its upper surface 115 mayinclude first and second surface zones 190 and 195 that may bepositioned at least partly over the respective first and second trusses90 and 95 of the understructure 80. The first and second surface zones190 and 195 may, but need not, have identical dimensions, such asidentical lengths and widths. The first and second surface zones 190 and195 may comprise continuous flat surfaces that form part of the uppersurface 115, or they may include features such as longitudinal grooves.Additionally, the first and second surface zones 190 and 195 may becoplanar or they may slope downward from their respective longitudinaledges 200 and 205 toward the midline 110. Also, the first and secondsurface zones 190 and 195 may be separated by a bridge 210 that spans atleast a portion of the distance between the first and second trusses 90and 95 of the understructure 80. The bridge 210 may also be coplanarwith the first and second surface zones 190 and 195 or may include astiffener or other feature such as a flute or medial furrow 215. Theload-bearing upper structure 85 may be bilaterally symmetrical.

The understructure 80 may also be, but need not be, bilaterallysymmetrical. The components of the first and second trusses 90 of theunderstructure 80 may form multiple U-bends. For example, in theembodiment depicted in FIG. 5, the first strut 100, the first cross beam105, and the second strut 125 may form a U-bend; the third strut 140,the third cross beam 145, and the fourth strut 150 may form a U-bend;the fifth strut 155, the fourth cross beam 160, and the sixth strut 165may form a U-bend; and the seventh strut 175, the sixth cross beam 180,and the eighth strut 185 may form a U-bend. These U-bends may havesimilar or different sizes. Additionally, the second strut 125, thesecond cross beam 130, and the third strut 140 may form an invertedU-bend; and the sixth strut 165, the fifth cross beam 170, and theseventh strut 175 may form an inverted U-bend. The inverted U-bends mayhave similar or different sizes with respect to each other or withrespect to the non-inverted U-bends. One will appreciate that while theembodiment shown in FIG. 5 exhibits rounded edges (such as the edges ofthe U-bends or the edges of the load-bearing upper structure) that mayfacilitate rolling or extrusions process, these edges may bemanufactured to form substantially transverse angles that may, or maynot, be perpendicular.

One or more of the U-bends, the central space 220 under the bridge 210,or other features of the substructure 80 may form longitudinal channelsto provide passage for a hydraulic line (not shown) that conveyshydraulic power from a hydraulic power source (not shown).

FIGS. 6A and 6B (collectively FIG. 6) illustrate a front left isometricview and a cross-sectional view, respectively, of an elongate body 50 a,according to an alternative embodiment; and FIG. 6C illustrates a frontleft isometric view of an elongate body 50 b, according to anotheralternative embodiment. With reference to FIG. 6, the functions of theelongate body 50 a and the elongate body 50 b (collectively elongatebody 50) are the same; however, their cross-sectional profiles aredifferent. The elongate body 50 a includes a load-bearing upperstructure 240 extending longitudinally from a first end 245 to a secondend 250. The load-bearing upper structure 240 comprises one or moresurface zones 255, such as flat surfaces, and is coupled to asubstructure 260 that may include a first truss 265 and a second truss270 as discussed below. In some embodiments, the surface zone(s) 255 maybe rigidly connected to one or more stiffeners 275, such as flutes.Stiffeners may be integrally formed with the surface zone(s) 255 toaccomplish a rigid connection or may be welded or otherwise suitablysecured to the flat surfaces. Stiffeners 275 may provide resistanceagainst longitudinal bending of the flat surfaces, such as the surfacezones 255. Alternate stiffeners include inverted flutes, fins 350 (see,e.g., FIG. 7), and other suitable structures that inhibit longitudinalbending of the flat surfaces. Stiffeners may protrude above the flatsurfaces or may protrude below the flat surfaces.

The substructure 260 forms a structural element that resists one or moreof flex, torsion, axial compression, and/or lateral deflection of theload-bearing upper structure 240. The first truss 265 includes a firststrut 280 that extends downward from the outer edge of the load-bearingupper structure 240 in a generally orthogonal orientation with respectto the load-bearing upper structure 240. A first cross beam 285 iscoupled to the first strut 280 and extends away from the first strut280, for example, substantially orthogonally from the first strut 280(toward the midline 290 of the elongate body 50) to form a lower surface295 of the elongate body 50. A second strut 300 is coupled to the firstcross beam 285 and extends from the first cross beam 285 towards theload-bearing upper structure 240. The second strut 300 may benon-perpendicular (e.g., positioned in a diagonal plane) with respect tothe load-bearing upper structure 240 to enhance the stiffness andtorsion-resistance of the elongate body 50.

A second cross beam 305 is coupled to the second strut 300 and maycontact a lower surface 310 of the load-bearing upper structure 240. Thesecond cross beam 305 can be coupled to the load-bearing upper structure240, for example, via spot welds or by being integrally formed with theload-bearing upper structure 240. A third strut 315 is coupled to thesecond cross beam 305 and extends from the second cross beam 305 awayfrom the load-bearing upper structure 240. The third strut 315 may benon-perpendicular (e.g., positioned in a diagonal plane) with respect tothe load-bearing upper structure 240 to enhance the stiffness andtorsion-resistance of the elongate body 50. A third cross beam 320 iscoupled to the third strut 315 and extends away from the third strut 315(away from the midline 290 of the elongate body 50) to form anotherlower surface 295 of the elongate body 50. A fourth strut 325 extendsfrom the third cross beam 94 towards the load-bearing upper structure240 and is coupled to the other outer edge of the load-bearing upperstructure 240.

In some embodiments, the substructure 260 may be coupled to theload-bearing upper structure 240 via welding. The substructure 260 maybe integrally formed with the load-bearing upper structure 240.Alternatively, the substructure 260 may be partially integrally formedwith the load-bearing upper structure 240 and secured to theload-bearing upper structure 240 via welding or other suitableattachment. Likewise, elements of the substructure 260 may be integrallyformed together, may be welded or otherwise suitably attached together,or may be coupled via a combination of integral formation and attachmentsuch as welding.

The second cross beam 305 may be substantially parallel to theload-bearing upper structure 240, may contact and/or be secured to orformed as part of the lower surface 310 of the load-bearing upperstructure 240, and may act as a second load-bearing member. Coupling thesecond cross beam 305 and the load-bearing upper structure 240 to oneanother, or forming them together, may reduce sliding between them whenthey are placed under load.

The load-bearing upper structure 240 and the first strut 280, the firstcross beam 285, and the second strut 300 of the first truss 265 may forma side channel 330. The load-bearing upper structure 240 and the thirdstrut 315, the third cross beam 320, and the fourth strut 325 of thesecond truss 270 may form a side channel 335. The first truss 265 andthe second truss 270 are spaced apart to form a central channel 340within the substructure 260 of the fork assembly 30. These channels mayprovide passage for a hydraulic line (not shown) that conveys hydraulicpower from a hydraulic power source (not shown).

With reference to FIG. 6C, the functions of the elongate body 50 b andthe elongate body 50 a (collectively elongate body 50) are the same;however, their cross-sectional profiles are different. The elongate body50 b of FIG. 6C is a squatter variation of the elongate body 50 a shownin FIG. 6A. Accordingly, FIGS. 6A and 6C share many of the samereference numerals.

FIG. 7 illustrates a cross-sectional view of another alternativeelongate body 50 c. With reference to FIG. 7, the elongate body 50 c andthe elongate body 50 (collectively elongate body 50) are substantiallyidentical with the exception of the stiffener fins 350. The plurality ofthe fins 350 may serve to form the upper-most surface of theload-bearing upper structure 85, and may support a load, such as apallet, thereupon.

FIGS. 8A, 8B, and 8C (collectively FIG. 8) illustrate a front rightbottom isometric view, a top front right isometric view, and a top frontright enlarged isometric view of portions of the elongate body 50 of themodular fork assembly 30, wherein the elongate body 50 is attached to anembodiment of endcaps 360 that form part of a first interlockingmechanism 365 (FIG. 4) that is configured for detachable connection ofthe elongate body 50 to the load wheel module 55. With reference toFIGS. 3, 4, and 8, the endcaps 360 may be configured for welding orother means of permanent or nonpermanent attachment to the proximaland/or distal ends 40 and 70 of the elongate body 50. In one example,the endcap 360 may have an endcap body 385 (FIG. 4D) between an externalside 370 and an internal side 375 (FIG. 4E) with respect to how theendcap 360 is positioned on the end of the elongate body 50, such thatthe internal side 375 is closest to the elongate body 50 and theexternal side 370 is farthest from the elongate body 50 and exposedoutwardly when the endcap 360 is connected to the elongate body 50.

The endcap 360 may include a beveled edge 390 between a side surface 395and the internal side 375. The beveled edge 390 may facilitate a snugfit between the endcap 360 and the proximal end 40 and/or distal end 70of the elongate body 50. The beveled edge 390 may also provide adequatespace or surface area to accommodate a superior weld between the endcap360 and the elongate body 50.

The endcap 360 may include one or more external flanges 380 that extendfrom the internal side 375 and are configured to slide into one or moreof the externally open channels formed in the understructure 80 and/orin the load-bearing upper structure 85. When welding is the desiredmeans of permanent attachment, the flanges 380 may be configured tocontact, and/or conform to the shape of, one or more exposed surfaces ofthe externally open channels, such as the exposed surfaces of the crossbeams 130 and 170 or the lower surface 135 beneath the bridge 210.

The endcap 360 may also include one or more prongs (not shown) thatextend from the internal side 375 and are configured to slide into oneor more of the closed channels formed by the understructure 80 and/orformed by a combination of portions of the understructure 80 and theload-bearing upper structure 85, such as closed channels 400. The prongsmay be configured to contact, and/or generally conform to the shape of,one or more of the surfaces of the closed channels 400, such as theinterior surfaces of the struts 100, 125, 140, 165, and 175, such as theinterior or exterior surfaces of struts 150 and 155, and/or such as thelower surface 135 within the channels 400. Each prong may include one ormore tabs or bumps that are configured to mate with crimps orindentations within the interior surfaces of the channels 400 and mayserve to hold or secure the endcaps 360 in place while they are weldedor more permanently attached by other means to the elongate bodies 50.

The endcaps 360 may form part of the first interlocking mechanism andmay include interlocking features that mate with interlocking featuresof alternative endcaps (not shown) or interlocking features configuredinto the body-facing end 65 of the load wheel module 55. One example ofinterlocking features includes one or more sheer-resistant features,such as protruding features 415 and respective mating receiving features420 (FIG. 4F). In particular, one of the protruding feature 415 or thereceiving feature 420 may be configured to permanently connect to theelongate body (or the endcap 360), and a different one of the protrudingfeature 415 or the receiving feature 420 may be configured topermanently connect to the load wheel module 55 (or an alternativeendcap if one is employed for the load wheel module 55).

In one example, the protruding features 415 may protrude from anexternal face 425 of the external side 370 of the endcap 360 and mayhave any shape that is adequate for engagement with respective receivingfeatures 420 configured in alternative endcaps or the interlockingfeatures in the body-facing end 65 of the load wheel module 55. Inparticular, the protruding features 415 may have a sectional profile ofany geometric shape. For example, the sectional profile of theprotruding features 415 may be circular as shown in FIG. 8, or thesectional profile may be another shape such as elliptical, rectangular,square, triangular, hexagonal, or octagonal.

The protruding features 415 may have any width or diameter that istypically smaller than dimensions of the external face 425 of theexternal side 370 (such that the protruding features 415 does not extendabove the load-bearing upper structure 85). A typical minimum width of aprotruding feature 415 might be about 25 mm. The protruding features 415may have any protruding height beyond the external face 425 of theexternal side 370 of the endcap 360 to the extent that the matedreceiving feature 420 would not interfere with operation of the loadwheel module 55. A typical minimum protruding height might be about 8mm.

Similarly, the receiving features 420 may have a sectional profile ofany geometric shape. For example, the sectional profile of the receivingfeatures 420 may be circular as shown in FIG. 4F, or the sectionalprofile may be elliptical, rectangular, square, triangular, hexagonal,or octagonal. Moreover, the receiving features 420 may have any width ordiameter that is typically smaller than dimensions of the external face425 of the external side 370. A typical minimum width of a receivingfeature 420 might be about 25 mm. The receiving features 420 may haveany depth into the mated interlocking feature to the extent that themated receiving feature 420 would not interfere with operation of theload wheel module 55. A typical minimum depth of receiving feature 420might be about 8 mm.

Although FIG. 8 depicts only two mated sets of protruding and receivingfeatures 415 and 420, additional sets, or only one, may be employed. Forexample, a set could additionally or alternatively be employed inproximity to one or more of the corners 435 of the external face 425(and respective face 450) of the body-facing end 65 of the load wheelmodule 55. One will also appreciate that the endcap 360 may employ oneor more of the receiving features 420 instead of the protruding features415. Alternatively, the endcap 360 may employ a mix of one or more ofthe receiving features 420 and one or more of the protruding features415. The mated endcaps or the interlocking features configured into thebody-facing end 65 of the load wheel module 55 would be configuredaccordingly to mate with the alternative configurations.

With reference again to FIG. 4A, the first interlocking mechanism 365may additionally or alternatively employ one or more fastener sets, suchas male and female mated fasteners. Any suitable mated fastener set canbe employed, such as threaded fasteners, unthreaded fasteners, orcompression fasteners. The embodiment shown in FIG. 4 employs externallythreaded fasteners 460 that are mated to one or more respectiveinternally threaded receptacles 465. The externally threaded fasteners460 may include a head 470, a shank 475, a thread 480, and a tip 485.The internally threaded receptacles 465 may include a head side 490,which is closest to the head 470 when the externally threaded fastener460 is mated to the internally threaded receptacle 465, and a tip side495, which is closest to the tip 485 when the externally threadedfastener 460 is mated to the internally threaded receptacle 465.

An example of externally threaded fasteners 460 includes 16-mmflange-head cap screws or bolts. One will appreciate that the diametercan be of any suitable size. However, a diameter large enough to aid inresistance to sheer between the detachably connected parts might bebeneficial. In some embodiments, the externally threaded receptacles 465have a minimum shank diameter of about 12 mm.

In the depicted embodiment, the endcap 360 includes multiple ones of thesame set of fasteners in the same respective engagement arrangements,such that all of the internally threaded receptacles 465 are configuredwith their head sides 490 closest to the external face 425 of the endcap360. However, one will appreciate that the endcap 360 could include oneor more internally threaded receptacles 465 configured with their headsides 490 closest to the external face 425 and one or more internallythreaded receptacles 465 configured with their tip sides 495 (hiddenwithin the flange 480 in connection with the interlocking mechanism 360but shown in FIG. 3D in connection with a second interlocking mechanism675) closest to the face 425. Alternatively or additionally, the endcap360 may be configured to include one or more different types of sets ofmated fasteners. In the embodiment shown in FIG. 4E, the tip side 495 isentirely hidden within the flange 480, but the internally threadedreceptacles 465 could be configured so that they form a tunnel all theway through the flanges 480.

In the example shown in FIG. 4, the sheer-resistant features areconfigured to incorporate one internally threaded receptacles 465. Inparticular, the protruding features 415 and the receiving features 420each have holes to receive the externally threaded fastener 460. Whenthreaded fasteners are employed, at least the protruding feature 415 orthe receiving feature 420 that is intended to be closest to the tip 485may be internally threaded (if a separate nut, for example, is notemployed). In the embodiment shown, the protruding features 415 of theendcap 360 include the internally threaded receptacles 465 because thewelding flanges 380 could be in the way of placing a nut or tighteningthe fastener head 470. One will appreciate that the design of theelongate body 50 or the endcap 360 can be modified to accommodateplacement of the head 470 of the externally threaded fastener 460, inwhich circumstances the sheer-resistant feature, such as the receivingfeature 420 in the body-facing end 65 of the load wheel module 55 couldbe configured to incorporate the internally threaded receptacles 465.However, if the fastener head 470 is to be closest to the body-facingend 65 of the load wheel module 55, then the shank holes 500 of thereceiving feature 420 in the body-facing end 65 of the load wheel module55 can be threaded or unthreaded.

FIG. 9A illustrates a front right bottom isometric view of a load wheelmodule 55 with a load wheel unit 510 in an undeployed position 440; FIG.9B illustrates a front right bottom isometric view of the load wheelmodule 55 with a load wheel unit 510 in a deployed position 445; andFIG. 9C illustrates a front right top isometric view of a wheel modulesubstructure 515. With reference to FIGS. 9A, 9B, and 9C (collectivelyFIG. 9), and additionally FIGS. 3 and 4, the load wheel module 55includes a frame 520 that houses the wheel module substructure 515. Theframe 520 includes a frame upper surface 525 and a frame lower surface530. The frame upper surface 525 may be configured to support andprovide sliding contact to a load, and the frame lower surface 530 maybe configured to provide one or more points of contact with componentsof the wheel module substructure 515.

The frame 520 may have a body-facing end 65 and a fork tip-facing end 75that may be substantially identical in shape or that may be different.For example, both of the body-facing end 65 and the fork tip-facing end75 may be configured to include substantially identical interlockingmechanism components. In particular, the sheer-resistant features, suchas the protruding features 415 or the receiving features 420 may beidentically positioned on both of the body-facing end 65 and the forktip-facing end 75. The wheel module assembly 55 depicted in FIG. 9includes receiving features 420 a configured into its fork tip-facingend 75. One will appreciate, however, that the body-facing end 65 andthe fork tip-facing end 75 may have different types of sheer-resistantfeatures in the same or different locations on each of the facing endsof the frame 520.

The frame 520 may also include an aperture 535 in both of thebody-facing end 65 and the fork tip-facing end 75 if symmetry is desiredfor manufacturing. However, in some embodiments, only the body-facingend 65 of the frame 520 may include the aperture 535 to provide passagefor a hydraulic line (not shown) that conveys hydraulic power from ahydraulic power source (not shown) to a hydraulic actuator 540 in theload wheel module 55. In other embodiments, the aperture 535 may providepassage for a mechanical link arm to facilitate lowering and raising aload wheel 565 via a suitable mechanical system coupled to the loadwheel module 55, where the mechanical link arm receives a motive forcefrom a power source located in a forklift truck body.

The wheel module substructure 515 may include a hydraulic actuatorassembly 545 and a load wheel assembly 550 that is operatively connectedto the frame 520. The load wheel assembly 550 includes a wheel carrierstrut 555 (also called a wheel carrier frame) that is operativelyconnected to, and supports, the load wheel unit 510 that includes awheel carrier 560 that supports one or more load wheels 565. In oneexample, the wheel carrier strut 555 has a U-shaped distal portion thatis pivotally connected to the wheel carrier 560 on both sides of theload wheels 560.

The wheel module substructure 515 may be positioned within the frame 520such that the hydraulic actuator assembly 545 is positioned closer tothe body-facing end 65 of the load wheel module 55 and the load wheelassembly 550 is positioned closer to the fork tip-facing end 75 of theload wheel module 55. In particular, the hydraulic actuator 540 may bepositioned closer to the body-facing end 65 and the load wheels 565 maybe positioned closer to the fork tip-facing end 75.

The wheel carrier strut 555 is also operatively connected to the loadwheel module frame 520 and to the hydraulic actuator assembly 545. Inone example, the operative connection to the frame 520 may beimplemented by one or more pivot bars 570 that may be pivotallyconnected at a bar frame end 575 to the frame 520 and at a bar strut end580 to the wheel carrier strut 555. Part of a pivot mechanism 585 at thebar frame end 575 may be secured within a recess 590 in an exterior sidesurface 595 of the frame 520 so that the part of the pivot mechanism 585will not catch when the modular fork assemblies 30 are slid into loadstructures that support the load. One will appreciate that other pivotmechanisms can additionally or alternatively be counter sunk into thecomponents that they are pivoting. For example, although not depicted inthis manner, part of the pivot mechanism 600 at the bar strut end 580may be recessed into the pivot bar 570.

An actuator-facing end 605 of the wheel carrier strut 555 may beoperatively connected to the hydraulic actuator assembly 545 via a pivotmechanism 610 at a strut-facing end 615 of the hydraulic actuatorassembly 545. The pivot mechanism 610 may include a pivot 620 thatextends through one or more strut teeth 625 at the actuator-facing end605 of the wheel carrier strut 555 that are interweaved with one or moreactuator assembly teeth 630 at the strut-facing end of the hydraulicactuator assembly 545.

The hydraulic actuator assembly 545 may include a hydraulic line inputconnector (also called a cap-end port) (not shown) operative forconnecting the hydraulic actuator 540 to a hydraulic line (not shown)that transmits hydraulic fluid from a hydraulic power source (notshown). The hydraulic line input connector may supply a hydraulicmanifold 640 that distributes hydraulic power from the hydraulic lineinto multiple hydraulic barrels (also called hydraulic cylinders) 645that each include a piston 650 (shown in broken lines in FIG. 9C) thatis operatively connected to a piston rod 655.

In some embodiments, the hydraulic actuator 540 may include from one toten pistons 650. In some embodiments, the hydraulic actuator 540includes at least two pistons 650. In some embodiments, the hydraulicactuator 540 may include from two to ten pistons 650. In someembodiments, the hydraulic actuator 540 includes at least three pistons650. In some embodiments, the hydraulic actuator 540 may include fromthree to eight pistons 650. In some embodiments, the hydraulic actuator540 may include from three to six pistons 650. FIG. 9C shows an exampleof a hydraulic actuator 540 that includes four hydraulic barrels 645,each of which includes a respective piston 650.

In one example, the piston 650 may have has a length within the range ofabout 0.50 inches to about 3 inches (or about 1.25 cm to about 7.75 cm)and a stroke length within the range of about 1 inch to about 3 inches(or about 2.50 cm to about 7.75 cm). In another example, the piston 650may have a length within the range of about 1 inch to about 2 inches (orabout 2.50 cm to about 5.25 cm) and a stroke length within the range ofabout 1.5 inches to about 2.5 inches (or about 3.75 cm to about 6.50cm).

In one example, the hydraulic barrels 645 have a capability up to about3,200 psi. In some embodiments, the hydraulic barrels 645 have acapability of greater than about 2,000 psi. In some embodiments, thehydraulic barrels 645 have a capability of greater than about 3,000 psi.In some embodiments, the hydraulic power from the hydraulic power sourcehas a maximum pressure within the range of about 13,790 to about 27,580kilopascals (about 2000 to about 4000 psi) at the hydraulic line inputconnector.

In some embodiments, the hydraulic actuator 540 is operable to providemaximum thrust within a range of about 15,000 pounds (or about 66,700newtons) to about 30,000 pounds (or about 133,500 newtons). In someembodiments, the hydraulic actuator 540 is operable to provide greaterthan about 15,000 pounds (or greater than about 66,750 newtons) ofthrust. In some embodiments, the hydraulic actuator 540 is operable toprovide greater than about 20,000 pounds (or greater than about 89,000newtons) of thrust.

The load wheel unit 510 may rest in an undeployed position 440 when thehydraulic actuator 540 is not actively pushing the piston rods 655beyond a cylinder head 660 of the piston assembly. The load wheel unit510 may be deployed into a deployed position 445 in response to a loadwheel deployment signal that may be provided by an automated system ormay be provided in response to a manually activated input, such as aswitch or button. The load wheel deployment signal directly orindirectly causes hydraulic power to be propagated through a hydraulicline positioned within the elongate body 50 of the modular fork assembly30. The hydraulic power may be in the form of a hydraulic fluid underpressure.

The hydraulic line delivers the hydraulic power through the hydraulicline input connector to the hydraulic manifold 640 that distributes thehydraulic power to the hydraulic barrels 645 of the hydraulic actuator540. The hydraulic power pushes the pistons 650 of the hydraulicactuator 540 so that the piston rods 655 extend beyond the cylinder head660 to push against the actuator-facing end 605 of the wheel carrierstrut 555, causing the pivot bar 570 to force the load wheel unit 510 toassume a predetermined deployed position 445 in which the load wheelunit 510 is vertically spaced apart from the load wheel module frame520. One will appreciate that the hydraulic line and hydraulic actuatorassembly 545 can be replaced by a link rod that is actuated close to theproximal end 40 of the elongate body 50 and a mechanical system coupledto the load wheel module 55 and arranged to lower and raise the loadwheel 565 in response to movement of the link rod. For example, asuitable mechanical system may be coupled to a load wheel module 55 witha link rod extending through an elongate body 50 of a fork assembly 30to mechanically connect the mechanical system with a power source suchthat force from the power source is transmitted via the link rod to themechanical system to lower and raise the load wheel 565.

With reference again to FIGS. 3 and 4, a second interlocking mechanism675 can be configured to detachably connect the load wheel module 55 tothe fork tip 60 or an endcap 670. The fork-tip facing end 75 of the loadwheel module 55 can be configured to mate with the proximal end 665 ofthe fork tip 60 or the endcap 670. The endcap 670 may form part of thesecond interlocking mechanism 675. The endcap 670 may be substantiallyidentical to, or different from, the endcap 360. Moreover, the secondinterlocking mechanism 675 may be substantially identical to, ordifferent from, the first interlocking mechanism 365. In the embodimentshown in FIG. 3D, the internally threaded receptacle 465 may beconfigured as a ferrule 685 that protrudes from the internal side of theendcap 670. The tip side 495 of the internally threaded receptacle 465may be open or closed.

All the alternatives described with respect to the first interlockingmechanism 365 may apply to the second interlocking mechanism 675. In onealternative embodiment, the fork-tip facing end 75 of the load wheelmodule 55 may be provided with the sheer-resistant protruding features415, and the endcap 670 or the proximal end 665 of the fork tip 60 maybe provided with the sheer-resistant receiving features 420.

The fork tip 60 has a distal end (also referred to as the toe end) 680that is opposite the proximal end 665, i.e., the distal end 680 isfurthest from the battery box 35. The distal end 680 of the fork tip 60initially engages a pallet when the modular fork assembly 30 is directedto pick up a load. The fork tip 60 may taper in one or more dimensionsfrom the proximal end 665 to the distal end 680 so that the perimeter ofthe distal end 680 is smaller than the perimeter of the proximal end665. In one example, the fork tip 60 and/or the distal end 680 has awedged shape. In another example, the distal end 680 has a curved shape.

A major advantage of the modularity of the modular fork assembly 30 isthat any one of the modular components, such as the elongate body 50,the load wheel module 55, or the fork tip 60, can be readily replaced ifthey become bent or otherwise damaged. Such replacement can be achievedwithout metal cutting or welding. In some embodiments, only a simpletool such as a screwdriver or wrench may be utilized to effect thereplacement. Moreover, these modular fork assemblies 30 and theircomponents may be readily salvaged from a disabled vehicle and reused ina working vehicle or as replacement parts.

While some of the examples have been illustrated or described withrespect to providing functionality for a “walkie” or “rider” stylepallet truck, some or all of the features may also be enabled foroperation with other types of industrial vehicles including, but notlimited to, reach trucks, three-wheel stand trucks, warehouse trucks,and counterbalanced trucks.

CONCLUSION

The terms and descriptions used above are set forth by way ofillustration and example only and are not meant as limitations. Thoseskilled in the art will recognize that many variations, enhancements andmodifications of the concepts described herein are possible withoutdeparting from the underlying principles of the invention. For example,skilled persons will appreciate that the subject matter of any sentenceor paragraph can be combined with subject matter of some or all of theother sentences or paragraphs, except where such combinations aremutually exclusive. The scope of the invention should therefore bedetermined only by the following claims, claims presented in acontinuation patent application, and equivalents to the foregoingclaims.

The invention claimed is:
 1. A fork assembly for a forkedmaterial-handling vehicle, the fork assembly comprising: a discreteelongate body; a discrete load wheel module configured for movement ofone or more load wheels between an undeployed position and a deployedposition; a first interlocking mechanism detachably connecting theelongate body to the load wheel module; a discrete fork tip; and asecond interlocking mechanism detachably connecting the load wheelmodule to the fork tip, wherein the first interlocking mechanism and thesecond interlocking mechanism are substantially identical, wherein theinterlocking mechanisms employ mated shear-resistant features includinga protruding feature that is mated to a receiving feature, wherein theprotruding feature protrudes from an external face of an external sideof an endcap associated with the elongate body, the load wheel module,or the fork tip.
 2. The fork assembly according to claim 1, wherein thefirst interlocking mechanism and the second interlocking mechanism areinterchangeable.
 3. The fork assembly according to claim 1, wherein thefirst interlocking mechanism and the second interlocking mechanismcontain an interchangeable component.
 4. The fork assembly according toclaim 1, wherein at least one of the first interlocking mechanism andthe second interlocking mechanism employs mated shear-resistantfeatures, including first and second sheer-resistant features.
 5. Thefork assembly according to claim 4, wherein the sheer-resistant featuresare configured to receive a fastener.
 6. The fork assembly according toclaim 1, wherein at least one of the first interlocking mechanism andthe second interlocking mechanism employs a mated internally threadedreceptacle and an externally threaded fastener.
 7. The fork assemblyaccording to claim 1, wherein the first interlocking mechanism employs afirst internally threaded receptacle that is mated to a first externallythreaded fastener, wherein one of the first internally threadedreceptacle and the first externally threaded fastener is configured toconnect to the elongate body, and wherein a different one of the firstinternally threaded receptacle and the first externally threadedfastener is configured to connect to the load wheel module.
 8. The forkassembly according to claim 1, wherein the first interlocking mechanismincludes a first protruding feature that is mated to a first receivingfeature, wherein one of the first protruding feature and the firstreceiving feature is permanently connected to the elongate body, whereina different one of the first protruding feature and the first receivingfeature is permanently connected to the load wheel module.
 9. The forkassembly according to claim 8, wherein both of the first protrudingfeature and the first receiving feature are configured to receive thefirst externally threaded fastener.
 10. The fork assembly according toclaim 1, wherein the first interlocking mechanism includes a firstendcap that is attached to the elongate body and includes a firstsheer-resistant body feature that is mated to a first sheer-resistantmodule feature of the load wheel module.
 11. The fork assembly accordingto claim 10, wherein the first endcap is welded to the elongate body.12. The fork assembly according to claim 10, wherein the secondinterlocking mechanism includes a second endcap that is attached to thefork tip and includes a second sheer-resistant attachment feature thatis mated to a second sheer-resistant module feature of the load wheelmodule, wherein the first and second interlocking mechanisms areoperatively identical.
 13. The fork assembly according to claim 10,wherein the second interlocking mechanism includes a second endcap thatis attached to the fork tip and includes a second sheer-resistantattachment feature that is mated to a second sheer-resistant modulefeature of the load wheel module.
 14. The fork assembly according toclaim 13, wherein the second sheer-resistant attachment feature and thesecond sheer-resistant module feature are adapted to receive a fastener.15. The fork assembly according to claim 1, wherein the elongate bodyhas a first characterizing color, wherein the load wheel module has asecond characterizing color, wherein the fork tip has a thirdcharacterizing color, and wherein the first, second, and thirdcharacterizing colors are different.
 16. The fork assembly according toclaim 1, wherein the load wheel module has opposing ends havingsubstantially identical sheer-resistant features.
 17. The fork assemblyaccording to claim 1, wherein the elongate body includes a channel alongits length, and wherein an endcap associated with the first interlockingmechanism includes an aperture that aligns with the channel.
 18. Thefork assembly according to claim 1, wherein the fork tip includes aproximal connection end for attachment closest to the load wheel module,wherein the proximal connection end has proximal end dimensions, whereinthe tip distal end has distal end dimensions, and wherein at least oneof the tip distal end dimensions is smaller than a respective one of theproximal end dimensions.
 19. The fork assembly according to claim 1,wherein the load wheel module comprises: a frame; a load wheel assembly,including a load wheel, operatively connected to the frame; and ahydraulic actuator contained within the frame and operatively connectedto the load wheel assembly to lower the load wheel hydraulically. 20.The fork assembly according to claim 1, wherein the load wheel modulecomprises: a frame; a load wheel assembly, including a load wheel,operatively connected to the frame; and a mechanical link operativelycoupled to the load wheel assembly to lower the load wheel, wherein themechanical link extends through the discrete elongate body.
 21. The forkassembly according to claim 1, wherein the forked material-handlingvehicle comprises a pallet truck.
 22. The fork assembly according toclaim 1, wherein the load wheel module is positioned between theelongate body and the fork tip.
 23. The fork assembly according to claim1, wherein the elongate body, the load wheel module, and the fork tipcomprise upper surfaces that are aligned substantially in the sameplane.
 24. The fork assembly according to claim 1, wherein the discretefork tip has a tip distal end that is configured to engage a pallet. 25.The fork assembly according to claim 1, wherein the load wheel moduleincludes a load wheel frame, and wherein the load wheel module employs apivotal connection between the load wheel frame and the one or more loadwheels.
 26. The fork assembly according to claim 1, wherein the forkedmaterial-handling vehicle is configured to employ two forks havingspaced-apart respective unobstructed distinct distal ends.
 27. The forkassembly according to claim 1, wherein the load wheel module has aframe, wherein the load wheel module is configured so that the one ormore load wheels are at least partly surrounded by the frame in theundeployed position and the one or more load wheels extend completelybeyond the frame in the deployed position.
 28. A pallet truck includinga fork assembly, the pallet truck comprising: a steer wheel; a chassisoperatively connected to the steer wheel; and two substantially parallelforks operatively connected to and extending from the chassis andconfigured to hold a load for conveyance by the pallet truck as thepallet truck moves, the forks including a first fork and a second fork,wherein the first fork comprises a first elongate body, a first loadwheel module, a first interlocking mechanism detachably connecting thefirst elongate body to the first load wheel module, a first fork tip,and a second interlocking mechanism detachably connecting the first loadwheel module to the first fork tip, wherein the first interlockingmechanism and the second interlocking mechanism are substantiallyidentical, and wherein the interlocking mechanisms employ matedshear-resistant features including a protruding feature that is mated toa receiving feature, wherein the protruding feature protrudes from anexternal face of the external side of an endcap associated with anelongate body, a load wheel module, or a fork tip, wherein the firstload wheel module is configured for movement of one or more first loadwheels between an undeployed position and a deployed position, whereinthe second fork comprises a second elongate body, a second load wheelmodule, a third interlocking mechanism detachably connecting the secondelongate body to the second load wheel module, a second fork tip, and afourth interlocking mechanism detachably connecting the second loadwheel module to the second fork tip, and wherein the second load wheelmodule is configured for movement of one or more second load wheelsbetween an undeployed position and a deployed position.
 29. The pallettruck of claim 28, wherein the first and second load wheel modules areinterchangeable, wherein the first and second tips are interchangeable,wherein the first and third interlocking mechanisms are interchangeable,and wherein the second and fourth interlocking mechanisms areinterchangeable.
 30. The pallet truck of claim 28, further comprising: ahydraulic power source; and a first hydraulic line positioned throughthe first elongate body, wherein the first hydraulic line transmitshydraulic fluid from the hydraulic power source to a first hydraulicactuator positioned completely within the first load wheel module. 31.The pallet truck of claim 28, further comprising: a power source; and afirst mechanical link positioned through the first elongate body,wherein the first mechanical link is configured to transmit force fromthe power source to a first load wheel mechanism positioned within thefirst load wheel module to lower the load wheel.
 32. The pallet truck ofclaim 28, wherein the first and second load wheel modules each comprise:a frame; a load wheel assembly, including a load wheel, operativelyconnected to the frame; and a hydraulic actuator contained within theframe and operatively connected to the load wheel assembly to lower theload wheel hydraulically.
 33. The pallet truck of claim 28, wherein atleast one of the first and third interlocking mechanisms includes afirst endcap that is attached to the elongate body and includes a firstsheer-resistant body feature that is mated to a first sheer-resistantmodule feature of the load wheel module.
 34. The pallet truck of claim28, wherein at least one of the first and third interlocking mechanismsincludes a first protruding feature that is mated to a first receivingfeature, wherein one of the first protruding feature and the firstreceiving feature is permanently connected to the elongate body, whereina different one of the first protruding feature and the first receivingfeature is permanently connected to the load wheel module.
 35. Thepallet truck of claim 28, wherein the first and second elongate bodieshave a first characterizing color, wherein the first and second loadwheel modules have a second characterizing color, wherein the first andsecond fork tips have a third characterizing color, and wherein thefirst, second, and third characterizing colors are different.
 36. Thepallet truck of claim 28, wherein the first load wheel module ispositioned between the first elongate body and the first fork tip. 37.The pallet truck of to claim 28, wherein the first elongate body, thefirst load wheel module, and first the fork tip comprise upper surfacesthat are aligned substantially in the same plane.
 38. The pallet truckaccording to claim 28, wherein the first fork tip has a first tip distalend that is configured to engage a pallet, and wherein the second forktip has a second tip distal end that is configured to engage the pallet.39. The pallet truck according to claim 28, wherein the first load wheelmodule includes a load wheel frame, and wherein the first load wheelmodule employs a pivotal connection between the load wheel frame and theone or more load wheels.
 40. The pallet truck according to claim 28,wherein the pallet truck is configured to employ two forks havingspaced-apart respective unobstructed distinct distal ends.
 41. Thepallet truck according to claim 28, wherein the load wheel module has aframe, wherein the load wheel module is configured so that the one ormore load wheels are at least partly surrounded by the frame in theundeployed position and the one or more load wheels extend completelybeyond the frame in the deployed position.
 42. A method of assembling afork for a forked material-handling vehicle, the method comprising:detachably connecting a first sheer-resistant body feature of a firstinterlocking mechanism to a first sheer-resistant module feature on aproximal end of a modular load wheel module, wherein the modular loadwheel module is configured for movement of one or more load wheelsbetween an undeployed position and a deployed position, wherein thefirst sheer-resistant body feature forms part of a first end cap that isattached to a distal end of a modular elongate body of the fork, andwherein the first sheer-resistant body feature is mated to the firstsheer-resistant body feature; and detachably connecting a secondsheer-resistant module feature at a distal end of the modular load wheelmodule to a second sheer-resistant attachment feature of secondinterlocking mechanism at a proximal end or an endcap of a modular forktip, wherein the second sheer-resistant attachment feature is mated to asecond sheer-resistant module feature, wherein the first interlockingmechanism and the second interlocking mechanism are substantiallyidentical, and wherein the interlocking mechanisms employ matedshear-resistant features including a protruding feature that is mated toa receiving feature, wherein the protruding feature protrudes from anexternal face of the external side of an endcap associated with anelongate body, a load wheel module, or a fork tip.
 43. The method ofclaim 42, comprising: connecting the modular elongate body to a batterybox or chassis of the forked material-handling vehicle.
 44. The methodof claim 42, comprising: connecting a hydraulic line through theelongate body to a hydraulic actuator completely within the modular loadwheel module.
 45. The method of claim 44, wherein the hydraulic linethrough the elongate body is configured to transmit hydraulic fluid fromthe hydraulic power source to the hydraulic actuator.
 46. The method ofclaim 42, wherein the modular elongate body is selected from one ofmultiple modular elongate bodies having substantially identical crosssections, wherein the modular load wheel module is selected from one ofmultiple interchangeable modular load wheel modules, and wherein themodular fork tip is selected from one of multiple interchangeablemodular fork tips.
 47. The method of claim 42, wherein the load wheelmodule is positioned between the elongate body and first fork tip. 48.The method of claim 42, wherein the elongate body, the load wheelmodule, and the fork tip comprise upper surfaces that are alignedsubstantially in the same plane.
 49. The method of claim 42, wherein themodular fork tip has a tip distal end that is configured to engage apallet.
 50. The method of claim 42, wherein the modular load wheelmodule includes a load wheel frame, and wherein the modular load wheelmodule employs a pivotal connection between the load wheel frame and theone or more load wheels.
 51. The method of claim 42, wherein the forkedmaterial-handling vehicle is configured to employ two forks havingspaced-apart respective unobstructed distinct distal ends.
 52. Themethod of claim 42, wherein the load wheel module has a frame, whereinthe load wheel module is configured so that the one or more load wheelsare at least partly surrounded by the frame in the undeployed positionand the one or more load wheels extend completely beyond the frame inthe deployed position.
 53. An inventory of parts for a fork assembly fora pallet truck, the inventory comprising: multiple interchangeableelongate bodies; multiple interchangeable load wheel modules, each loadwheel module configured for movement of one or more load wheels betweenan undeployed position and a deployed position; multiple interchangeablefork tips, wherein the multiple interchangeable fork tips each have atip distal end that is configured to engage a pallet; and multipleoperatively identical interlocking mechanism components configured fordetachable connection of any one of the elongate bodies to any one ofthe load wheel modules and configured for detachable connection of anyone of the fork tips to any one of the load wheel modules.
 54. Theinventory of parts of claim 53, wherein each of the load wheel modulesinclude a load wheel frame, and wherein each of the load wheel modulesemploy a pivotal connection between the load wheel frame and the one ormore load wheels.
 55. The inventory of parts of claim 53, wherein theload wheel module has a frame, wherein the load wheel module isconfigured so that the one or more load wheels are at least partlysurrounded by the frame in the undeployed position and the one or moreload wheels extend completely beyond the frame in the deployed position.56. The inventory of parts of claim 53, wherein the interlockingmechanisms include a first interlocking mechanism and a secondinterlocking mechanism that employ mated shear-resistant features,including first and second sheer-resistant features.
 57. The inventoryof parts of claim 56, wherein the sheer-resistant features areconfigured to receive a fastener.
 58. The inventory of parts of claim53, wherein the interlocking mechanisms include a first interlockingmechanism and a second interlocking mechanism that employ a matedinternally threaded receptacle and an externally threaded fastener. 59.The inventory of parts of claim 53, wherein the interlocking mechanismsinclude a first protruding feature that is mated to a first receivingfeature, wherein one of the first protruding feature and the firstreceiving feature is permanently connected to the elongate body, whereina different one of the first protruding feature and the first receivingfeature is permanently connected to the load wheel module.
 60. Aninventory of parts for a fork assembly for a pallet truck, the inventorycomprising: multiple interchangeable elongate bodies; multipleinterchangeable load wheel modules; multiple interchangeable fork tips;and multiple operatively identical interlocking mechanism componentsconfigured for detachable connection of any one of the elongate bodiesto any one of the load wheel modules and configured for detachableconnection of any one of the fork tips to any one of the load wheelmodules, wherein the interlocking mechanism components employ matedshear-resistant features including a protruding feature that is mated toa receiving feature, wherein the protruding feature protrudes from anexternal face of the external side of an endcap associated with anelongate body, a load wheel module, or a fork tip.
 61. The inventory ofparts of claim 60, wherein each of the load wheel modules include a loadwheel frame, and wherein each of the load wheel modules employ a pivotalconnection between the load wheel frame and the one or more load wheels.62. The inventory of parts of claim 60, wherein each of the load wheelmodules has a frame, wherein each load wheel module is configured sothat the one or more load wheels are at least partly surrounded by theframe in the undeployed position and the one or more load wheels extendcompletely beyond the frame in the deployed position.
 63. An inventoryof parts for a fork assembly for a pallet truck configured to employ twoforks having spaced-apart respective unobstructed distinct distal ends,the inventory comprising: multiple interchangeable elongate bodies;multiple interchangeable load wheel modules, each load wheel moduleconfigured for movement of one or more load wheels between an undeployedposition and a deployed position; multiple interchangeable fork tips;and multiple operatively identical interlocking mechanism componentsconfigured for detachable connection of any one of the elongate bodiesto any one of the load wheel modules and configured for detachableconnection of any one of the fork tips to any one of the load wheelmodules.